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Electrified Performance

Oct 20, 2015 - 4 years ago

By Supply Post

Terex CC 2800 Crawler Crane Quickly Changes Power Station Filters between Jobs

Heavy crane lift specialists, Havator of Tornio, Finland, maintains a heavy booking schedule for one of its oldest, more versatile and most reliable cranes in its fleet, a 2001-vintage Terex CC 2800 lattice boom crawler crane. Often the 600-tonne (660-US-ton) crane moves from job to job, never receiving a reprieve at the lifting company’s home office

Last lifting season is a prime example of just how much business Havator books for the CC 2800 crane. Over a relatively short period of time, the company moved the versatile Terex crane three times, logging over 350 km (217 mi), for three very different applications.

Havator first used the crawler crane in an industrial application, changing 62-tonne (68-US-ton) process washers at a paper mill in Pietarsaari, Finland. Crew members then loaded the crane on 15 trailers, plus three heavy haulers for the crane superstructure and crawlers, and led the convoy 250 km (155 mi) north over a three-day journey to Oulu for changing electric plant filters at the Toppila Power Station. The third leg of the trip saw the crane moving another 100 km (62 mi) north by land and then barged to an island for a windmill project to switch out turbine gears.

“The CC 2800 crane is fast to assemble and disassemble, quite easy to transport and flexible enough to be used on many different projects,” says Logistics Manager for Havator, Matti Simola. “We use it for industrial and windmill projects, but the lumber industry is where we use it most. This is just one of 60 Terex cranes we have in our fleet,” he continues.

Low Load & Confined
By far the most challenging of the three projects was the power station job. The four, 20-m (65.6-ft) tall, 20-year-old filters offered some excitement for Havator’s lifting crew and the CC 2800 crane. “The new filters weigh approximately 200 t (220 US tons) each,” explains Simola, “but the weight and condition of the old filters can be a bit of a mystery.”

One of the largest peat-fired power stations in the world, the Toppila Power Station generates 210 MW of electric power and 340 MW of thermal power. The four massive air filters pull from the airstream the particulate matter generated by the peat-burning process. The filters are changed on a 20-year cycle. “The filters are typically covered with dust, rust and other items, which can increase the filters’ weight,” comments Simola.

The 600-t (660-US-ton) capacity Terex crane was up to the challenge posed by the unknown. Havator configured the crane with its heavy boom segments, constructed the 42 m (138 ft) long main boom and added a 30-m (98-ft) luffing jib to reach the required 65-m (213-ft) hook height for filter removal. To help boost the crane’s lift capacities, Havator’s crew added 160 t (176 US tons) of counterweight to the main body of the CC 2800 crawler crane and another 275 t (303 US tons) onto the variable-radius Superlift tray. “We used the Terex Superlift wagon with wheels, which allows the tray to smoothly move back and forth as the crane works,” says Simola. “This helps to boost lift capacities as well as efficiencies.”

Since space was at a premium at the electric plant site, Havator chose the short boom/jib configuration and worked at a relatively narrow radius, ranging from 24- to 27-m (79- to 89-ft). “At the minimum radius in this configuration, the CC 2800 crane offers a lift capacity of up to 227 t (250 US tons) and 205.5 t (226.5 US-ton) capacity at the maximum working radius, so we built in extra lift capacity to account for the possibility of additional weight with the used filters,” adds Simola. Once on site, Havator’s rigging crew took just 2.5 days to set up the crane. This included additional steps required to meet the strict 15 t/m2 (1.5 US-ton/ft2) ground load pressure limit. Even though the crane’s weight is spread over its large crawler tracks’ 31-m2 (332-ft2) area, the CC 2800 crane could not reach the relatively low load limit for the job.

“We had to strictly adhere to the ground load pressure limit, because of the risk of damaging the many pipes and canals running under the ground,” explains Simola. “We placed multiple special kinds of pontoon plates under the lifting/driving area. They are approximately 6.5-m-long by 3.5-m-wide by 0.6-m-thick (21.3- x 11.5- x 2.0-ft).” For contractors that often face applications with low ground load pressure restrictions, Terex offers 1.8-m (4.9-ft) wide crawler tracks, so weight can be disbursed over a wider area.

Over the next week and a half, Havator’s two crane operators, supervisor and radioman used the Terex CC 2800 crawler crane to perform the eight major picks – four to remove the old filters and four to install the new – and several minor lifts. “We had to carry the load of the old filters over a distance, so it was necessary to use the crawler crane,” says Simola. The used filters were placed on a special Havator trailer that carried them over to the assigned storage location, approximately 300 m (984 ft) from the lift area.

The CC 2800 crane performed flawlessly removing and replacing the 20-m-long by 10-m-deep by 20-m-high (65.6- x 32.8- x 65.6-ft) filters. “Everything went well,” says Simola. “We worked according to plan and completed the job on time.” Then the crews quickly dismantled the crane, loaded it back onto the 15 trailers and three heavy trailers, and moved it to Kemi for the windmill project.

After the Kemi windmill project and an extended period away from the office, the CC 2800 crane made its way back to Havator’s Torino yard for a scheduled inspection. “We had Clemens Marx (Field Technician for Terex Cranes) visit our office to conduct a thorough, 10-year inspection of our CC 2800 crane,” mentions Simola. “Based on his findings, we renovated the winches, boom sections, engine, sheaves, bearings and pendants, and it’s now operating like a new crane.”

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